2021 Yamaha YZ250 Service & Repair Manual

Repair&ServiceManual<1ew, V1 guke=YZ250FMONSTER YZ250F Owner’sServiceManual - )i

L\WARNING:Operating,servicingand maintainingapassengervehicleoroff-roadvehiclecan exposeyoutochemicalsincludingengineexhaust, carbonmonoxide,phthalates,andlead,whichare knowntotheStateofCaliforniatocausecancerand birthdefectsorotherreproductiveharm.Tominimize exposure,avoidbreathingexhaust,donotidlethe engineexceptasnecessary,serviceyourvehicleina well-ventilatedareaandwearglovesorwashyour handsfrequentlywhenservicingyourvehicle.Formore informationgoto www.P65Warnings.ca.gov/passenger-vehicle

Q\Readthismanualcarefullybeforeoperatingthisvehicle.Thismanualshouldstaywiththisvehicle ifitissold. FCCCAUTION Changesormodificationsnotexpresslyapprovedbythepartyresponsibleforcompliancecouldvoidtheuser's authoritytooperatetheequipment. Thistransmittermustnotbeco-locatedoroperatedinconjunctionwithanyotherantennaortransmitter. ThisequipmentcomplieswithFCCradiationexposurelimitssetforthforanuncontrolledenvironmentandmeets theFCCradiofrequency(RF)ExposureGuidelines.ThisequipmenthasverylowlevelsofRFenergythatis deemedtocomplywithoutmaximumpermissiveexposureevaluation(MPE).

YZ250FM OWNER’SSERVICEMANUAL ©2021byYamahaMotorCorporation,U.S.A. Firstedition,June2020 Allrightsreserved. Anyreproductionorunauthorizeduse withoutthewrittenpermissionof YamahaMotorCorporation,U.S.A. isexpresslyprohibited. PIN.LIT-11626-34-25

IMPORTANT CongratulationsonyourpurchaseofaYamahaYZseries.ThismodelistheculminationofYamaha’s vastexperienceintheproductionofpacesettingracingmachines.Itrepresentsthehighestgradeof craftsmanshipandreliabilitythathavemadeYamahaaleader. Thismanualexplainsoperation,inspection,basicmaintenanceandtuningofyourmachine.Ifyouhave anyquestionsaboutthismanualoryourmachine,pleasecontactyourYamahadealer. TIP *Yamahacontinuallyseeksadvancementsinproductdesignandquality.Therefore,whilethismanual containsthemostcurrentproductinformationavailableatthetimeofprinting,theremaybeminordis- crepanciesbetweenyourmachineandthismanual.Ifyouhaveanyquestionsconcerningthismanual,pleaseconsultyourYamahadealer. *Thismanualisintendedforthosewhohavebasicknowledgeandskillconcemingtheservicingof Yamahamotorcycles(e.g.,Yamahadealers,serviceengineers,etc.).Thosewhohavelittleknowledgeandskillconcerningservicingarerequestednottoundertakeinspection,adjustment,disassembly,orreassemblyonlybyreferencetothismanual.Itmayleadtoservicingtroubleandmechanical damage. PLEASEREADTHISMANUALCAREFULLYANDCOMPLETELYBEFOREOPERATINGTHIS MACHINE.DONOTATTEMPTTOOPERATETHISMACHINEUNTILYOUHAVEATTAINEDA SATISFACTORYKNOWLEDGEOFITSCONTROLSANDOPERATINGFEATURESANDUNTIL YOUHAVEBEENTRAINEDINSAFEANDPROPERRIDINGTECHNIQUES.REGULARINSPEC- TIONSANDCAREFULMAINTENANCE,ALONGWITHGOODRIDINGSKILLS,WILLENSURE THATYOUSAFETYENJOYTHECAPABILITIESANDTHERELIABILITYOFTHISMACHINE. IMPORTANTMANUALINFORMATION Particularlyimportantinformationisdistinguishedinthismanualbythefollowingnotations. Thisisthesafetyalertsymbol.Itisusedtoalertyoutopotentialper- adsonalinjuryhazards.Obeyallsafetymessagesthatfollowthissymbol toavoidpossibleinjuryordeath. AWARNINGindicatesahazardoussituationwhich,ifnotavoided,could AWARNINGresultindeathorseriousinjury. ANOTICEindicatesspecialprecautionsthatmustbetakentoavoid NOTICEdamagetothevehicleorotherproperty. TIPAIPprovideskeyinformationtomakeprocedureseasieror clearer.

YAMAHAMOTORCORPORATION,U.S.A.YZMOTORCYCLELIMITED WARRANTY ‘YamahaMotorCorgration,USA.herebywarrants 1theorginalrtalpurchasertnttheflowing ‘componentsequippedonnewamnahaYZ ImotoreylespurchasedfrmanauthorizedYamane ImoloreyesedosesinhecontinentalUniedSatesvs beeomdolacsinei!areworkmanshipfoe thoporiodoftmestadheron,subjecttoconn Statdimtaons.YZcomponentsincudedundertis ‘warrantyareteengine.fame,swingarm.and Imonoahock.Itsunderstoodthatthebalance oftha YYZcompanentaarenotcoveredbyarywaranty ‘expressedorimplied.Thebalanceofthe ‘ormponentsecuntheuriaresoldana"98 ie"basis.Thewrantyapplestotheorginal purchaseronlyandsnolanaes, ‘THEPERIODOFWARRANTYforthesbove-tes ‘Yamana YZcompanentsa8orginalitalonthe unshallbetity(90)daysfromthedateof MODELSEXCLUDEDFROMWARRANTYince thoseusedfornon-Yamaha-authorzed.renting, leasing,oFetorconmarialpurposes, DURINGTHEPERIODOFWARRANTYany sutborzeaYamahamotoryeledealerwil,feeof ‘charge,rena0”replace,atYamaha'soptionany atadjudgeddetectivebyYamahadueto‘auly ‘orkmarshipomaleomthefactory.Parsused inwarantyraewtbewarranodforhobans oftheproductswarantypared.Atpartsroplacse underwarrantybecomepropertyofYamahaMotor Comecaton.USA GENERALEXCLUSIONSfromthiswarrantyshat Includeanytalescausedby: 4Instalatonofparsoracosssoriesthatarenot ‘uaitetivlyaquvalanttogenuine.Yamana pat. Abnormstrain,neglect,orabuse. econocolisiondamage 44Nositeaontoginalparts ©Lack ofpropermaitonanes 1Damagedue toimpropertransportation, SPECIFICEXCLUSIONSfromthiswarrantyshall Ineudepatreplaceddutonarmalwearoouting ‘THECUSTOMER'SRESPONSIBILITYunderthis warantyshallbo 1.OperateandmaintainthoYZaspectedintho appropiateOuner'ServiceMaral,and 2GiveteaoanauthoransYamahamotorola earofanyandalapparentderetswithinten (10)daysateralscovery,andmaketemactine Avalableatthaltimeforinspectionandreps fatshdealer'splaceofbusiness YAMAHAMOTORCORPORATION,USA.MAKES [NOOTHERWARRANTYOFANYKIND,EXPRESSED (ORIMPLIED.ALLIMPLIEDWARRANTIESOF MERCHANTABILITYANDFITNESSFORA PARTICULARPURPOSEWHICHEXCEEDTHE OBLIGATIONSANDTIMELIMITSSTATEDINTHIS WARRANTYAREHEREBYDISCLAIMEDBY YAMAHAMOTORCORPORATION,US.A.AND EXCLUDEDFROUTHISWARRANTY. ‘SOMESTATESDONOTALLOWLIWNTATIONSON HOWLONGANIMPLIEDWARRANTYLASTS,SO THEABOVELAWTATIONMAYNOTAPPLYTOYOU. ‘ALSOEXCLUDEDFROMTHISWARRANTYARE ANYINCIDENTALORCONSEQUENTIALDAMAGES INCLUDINGLOSSOFUSE.SOMESTATESDONOT ALLOWTHEEXCLUSIONORLIMITATIONOF INCIDENTALOFCONSEQUENTIALDAMAGES,SO THEABOVEEXCLUSIONMAYNOTAPPLYTOYOU. THISWARRANTYGIVESYOUSPECIFICLEGAL RIGHTS,ANDYOUMAYALSOHAVEOTHER [RIGHTSWHICHVARYFROMSTATETOSTATE YAMAHAMOTORCORPORATION,USA cypress,Callin80630, WARRANTYQUESTIONSANDANSWERS 10.oesthewarantycoverinitaletschaowingorransportationdus0fi A.YostouaaliedmachanicandfollowheproceduresspeciintheOwner's ©.wahemany beiecreif0peerminynYEon barclrfaraixcoudbyapeationormaintenanceetherthanaeshowninthe ‘umeServiceManatatlle mayaotbecoveredundewarranty, 1.Whatexponsiitydoesmydeslerhaveunserhiewatranty? [AEacnYamanamotorcycledeaionpoted0 CUSTOMERSERVICE Sharerofhedeslerani.SincealwarantymatesarePandastedesler Tovthisparaoniinthobespostiontehalpyou.Youaesilntsosog ‘CHANGEOFADDRESS. sceusofyournowasecbysending»psteatéhingyourmevareyee ‘rode!sams,VNframenumer)seslarnumbefordealsame)See YAMAHAMOIORCORPORAIION,USA, CypressCalter0859

HOWTOUSETHISMANUAL Inthismanual,descriptionsofinstallation,removal,disassembly,assembly,check,andadjustment proceduresarelaidoutwiththeindividualstepsinsequentialorder. *Themanualisdividedintochaptersandeachchapterisdividedintosections.Thecurrentsectiontitle “4”isshownatthetopofeachpage. *Sub-sectiontitles“2”appearinsmallerprintthanthesectiontitle. *Tohelpidentifypartsandclarifyproceduresteps,thereareexplodeddiagrams“ removalanddisassemblysection. *Numbers“4”aregivenintheorderofthejobsintheexplodeddiagram.Anumberindicatesaremoval oradisassemblystep. *Symbols“S”indicatepartstobelubricatedorreplaced. Referto“SYMBOLS”. *Ajobinstructionchart“6”accompaniestheexplodeddiagram,providingtheorderofjobs,thenames ofparts,thenotesinjobs,etc.Thisstepexplainsremovalanddisassemblyprocedureonly.Forinstallationandassemblyprocedure,reversethesteps. *Jobs“7”requiringmoreinformation(suchasspecialtoolsandtechnicaldata)aredescribedsequen- tially. atthestartofeach cuuTeHcuuteH cosee77

SYMBOLS Thefollowingsymbolsareusedinthismanualforeasierunderstanding. TIP Thefollowingsymbolsarenotrelevanttoeveryvehicle. SYMBOLDEFINITIONSYMBOLDEFINITION Serviceablewithenginemounted4Gearoil Fillingfluid4Molybdenumdisulfideoil Lubricant4Brakefluid Specialtool3A|Whoo!bearinggrease Tighteningtorque Lithium-soap-basedgrease Wearlimit,clearance Molybdenumdisulfidegrease Enginespeed Siliconegrease Electricaldata Applylockingagent(LOCTITE®). BES] yl Sel ie Engineoil New Replacethepartwithanewone.

~TABLEOFCONTENTS GENERALINFORMATION SPECIFICATIONS PERIODICCHECKSAND ADJUSTMENTS CHASSIS ENGINE COOLINGSYSTEM FUELSYSTEM ELECTRICALSYSTEM TROUBLESHOOTING TUNING LSlololrl[olalalwlnrn] |

2021 Yamaha YZ250 Service & Repair Manual

You're Reading a Preview

Recently Viewed